Kohler Head Gasket Diagnosis Replacement and Repair Courage SV610 21HP Engine

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We replace air cleaner, head gasket, valve cover gasket, intake gaskets and exhaust gasket on a Kohler Courage 21hp Engine Model SV610-0211 on a Toro Timecutter Z4220 diagnosis and repair
This unit ran alright until it was under a load surprisingly but was leaking oil from the head.
Smoke was visible coming from the crankcase.
The oil reservoir was smoking from dipstick, intake and head
The head gasket part number is 20 841 01-S ( amzn.to/46PSixZ )
The air filter part number is 20 083 06-s
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About Us:
My name is Martin. I have been repairing tools and small engines for almost 20 years. We operate a small engine repair shop in Illinois. We service / repair Briggs & Stratton, Kohler, Kawasaki, John Deere, Cub Cadet, Toro Tecumseh, Loncin, Honda, Craftsman, Husqvarna, MTD, Troy Bilt, Simplicity, John Deere, Exmark, LCT, Generac and many more brands. We work on riding mowers, walk behind mowers, snow blowers, zero turns, generators, pressure washers and much more. We normally repair about 3,000 pieces of equipment every year and look at many more that are beyond an affordable repair. Hopefully our videos will save you some money and give you the information you need to work on your own equipment or figure out the issue at hand.
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Please be careful when repairing any piece of equipment and follow all possible safety measures. This video is for entertainment purposes only.

[@user-pz5in8wi9d]

Just enough dialog. Glad valve lash and torque specs were included. A+. Thank you !!

[@IndRepair]

Appreciate that. Thanks for watching!

[@JoshuaCollins]

Thanks for making this. I'm doing a head gasket on an SV600-0025 and your video makes for a great guide. Cheers 🍻

[@IndRepair]

Thanks for watching!

[@JoshuaCollins]

@@IndRepair so I did the head gasket yesterday. Followed the Kohler service manual to a t. When it came time to start it she cranked right up. Ran for about 20 seconds shut off and now when I turn the key the only thing that happens is the fuel solenoid actuates. If I jump the starter it will activate, but with the key nothing. I don't understand what's going on I've tested all the switches. Could it just be coincidence? Do you have any idea what could be going on here? And yes. I've tested the key switch. 12 volts is being sent to the starter solenoid when the key is turned. However there is no click at the solenoid. I purchased another solenoid it has the same behavior. The ground connected to the solenoid has zero resistance when tested. 🤷‍♂️🤷‍♂️

[@IndRepair]

I would make sure all connections are tight and ground wire is secure

[@JoshuaCollins]

@@IndRepair Im so dumb. The brake switch was disconnected. However it does not idle smoothly and smoke is still coming out from the oil dipstick tube when it runs. This is with a brand new head gasket!

[@IndRepair]

Is the oil level correct and not overfilled? You could have a valve that is not seating properly or a timing issue

[@davedave3631]

I’d like to see a video of your tool preferences to make your job easier. I don’t know if you’re an Amazon affiliate but there is some money to be made by doing that. You could link the tools and parts you prefer (even if it didn’t actually buy them through Amazon) which would help us be more informed while adding monthly to your account at the same time. A win-win, really.

[@davedave3631]

Money, not monthly. I don’t know how to edit comments on here.

[@IndRepair]

May just do this! Thanks for watching!

[@Scott-id7pq]

Thanks for the video....You made it look to easy. Heading to the carport to replace all my gasket's now. I got the kit.

[@IndRepair]

Awesome!! You got it!

[@GY6SCOOTERCHAT]

One of the better videos on this topic. Thanks

[@IndRepair]

Thanks for watching!

[@waltergrady2501]

You have gave me a good lesson thank you

[@IndRepair]

Thank you for watching!

[@davidcantrell64]

Great detailed video man!! Pretty sure this is what’s wrong with mine

[@IndRepair]

Awesome! Thanks for watching!!!

[@desotopete]

That gasket behind the heat shield blown out had me confused for a year. Mine was blown out like that but didn't think it would matter cause it was blown out in the middle not the edge. So far so good or until the next problem pops up. Mine never had that metal heat shield behind the plastic heat shield. Bought new.

[@IndRepair]

Nice!

[@drewmcdowell7684]

Not related to headgaskets but I have a similar kohler courage, wondering exactly what the plastic intake port insert is for? It's shown in your video, but there's no mention of it. I can't seem to find anything online about it.

[@IndRepair]

I am not 100% sure, I have always thought it is just for certain models/applications and it depends on horsepower needed but seems to be in every one. 🤔

[@drewmcdowell7684]

@IndRepair thanks. Mines a 20hp. Just put a new carb on it Friday trying to fix surging and only running on choke. Found that the gasket from the carb to the intake (the one with the large square of gasket material) was blown out) hopefully that fixes it. Will know in a couple of days once I install the new gasket. As far as the port insert goes, I think it's got to do with directing air/fuel into the combustion chamber. Not sure though, also not sure of proper installation of it, and concerned about how loose they sit inside the intake. Wish kohler would have put some information out on it. 🙄

[@mattjford473]

Great video

[@IndRepair]

Appreciate that! Thanks for watching!

[@paavo6886]

Thank you for the detailed video. I am going through this process right now and its very helpful. Question about the pushrods, I had left them in the head so I didnt get them mixed up but as I was cleaning the head I accidentally let them fall out and now I dont know which is which, is this a large problem? Thank you

[@IndRepair]

The push rods are the same for exhaust and intake on this model. We see then damaged often so check well and adjust valves to spec

[@paavo6886]

@@IndRepair Thank you for the reply, I appreciate it!

[@Highperez76]

Question: Do I need put the silicone in the gasket valve?

[@IndRepair]

Not required

[@DavidRidilla]

Great video, seems similar to my SV590 (19hp). When I removed the valves oil started pouring out of my head - is that a job you are not supposed to do with oil filled? I also saw there is a drainback tube part number but I don't believe I have that so I had to hot swap gaskets while the bottom right port hole leaked out, hopefully that didn't compromise the seal.

[@IndRepair]

There will be oil in the valve cover and head but the majority of the oil will stay in the engine during the process

[@qryche1967]

I have a Kohler SV610-0212 21hp with no fuel pump. Mine does have the metal heat plate behind the carb, I wonder if this was an oversight by the factory or some models come without? This mower was purchased new and carb has never been taken off. Also, if the back intake gasket is blown will that make it run like it's not getting enough gas?

[@IndRepair]

There should be a plastic adapter, one that holds one of the intake studs in it. The two back gaskets, between the carburetor and the plastic and between the block and the plastic are the ones that will change how a mower runs. If there is a leak in either you will get erratic running, popping, sputters, backfiring or any number of other things. If there is a leak in front of the carburetor (towards air cleaner) it will still run ok but will pull in whatever debris gets into the area. Thanks for watching!

[@qryche1967]

@@IndRepair Sorry for the confusion, I just noticed I made a mistake in my question. Mine does NOT have the metal plate like the one in your video, but it does have the plastic one, so I am guessing my sv16-0212 did not come with the metal plate. Turns out the very back intake gasket was blown and made me think the carb was bad. I purchased a new $175 carb and the $7 gasket and it turns out it was only the gasket. My $175 DIYer mistake.

[@IndRepair]

That does happen sometimes when trying to do it yourself. On the bright side you would have spent that new carb money on labor had you taken it somewhere instead of doing it yourself. Now you have everything in good shape and it should run like new!

[@richardcole6566]

can I use blue lock tight on head bolts and value cover bolts? Good presentation thank you

[@IndRepair]

Do not use loctite in these areas or any time when reassembling an engine except in special circumstances. Thanks for watching!

[@killerkory85]

Does opening the oil fill cap while running and having crank pressure also mean head gasket failure? I have a simplicity with a 20 hp kohler SV600

[@IndRepair]

You should have some crankcase pressure when the engine is running but it should not be a lot

[@killerkory85]

Okay thanks. The mower doesn’t like cold starts with the choke on, seems to start better with the choke off and the throttle about 1/4 way up. Just seems a little odd to me. Doesn’t seem to smoke or lose power. Oil is a little above full mark but it was just serviced by pervious owner, can’t seem to tell if it has a fuel smell or just an oil smell if that makes sense

[@IndRepair]

If it's not starting with the choke on easily and oil smells anything like fuel you probably have a leaky needle/seat which is giving the mower some fuel into the piaton/cylinder while sitting. I see this happen with these motors with the vacuum fuel pump regularly

[@jikijoel]

I have a sv610 020. I'm trying to find the right gasket kit for it. Is this the same kit? Thanks

[@IndRepair]

Should be Kohler 20-841-01-S

[@jikijoel]

@@IndRepair thank you. I was having a hard time trying to find the part number.

[@DMY.Dav1d]

I replaced the head gasket on my Kohler courage 19 with a rtv gasket and after i put it back together I doesn’t wanna start. Pls help

[@IndRepair]

Rtv is not good for a head gasket. Use an OEM head gasket for this

[@DMY.Dav1d]

@@IndRepair wouldn’t it still start with rtv

[@IndRepair]

Not sure, never done it but definitely needs redone. If it does start it will only run once

[@DMY.Dav1d]

@@IndRepair Ok i just dont wanna buy the gasket kit and have it still not run and i also ordered a carb that is coming in a few days that i am not sure if it will fix it

[@IndRepair]

Must run with OEM head gasket for sure, too much pressure for RTV to handle. Soon as it heats up that much it blows out. Not meant for the heat/pressure

[@mattjford473]

How can I free up a head bolt on the same size motor if it won’t come loose

[@IndRepair]

More torque should do it normally

[@philliphall5198]

How many hours of labor should I charge for this type of repair, I’m 72 and slow so I don’t wont to over charge them

[@IndRepair]

2 hours labor or less normally if just the head gasket kit being done

[@philliphall5198]

Thank You for information and advice

[@stevez9764]

thanks for a great video . Just did mine and it works perfectly

[@IndRepair]

Awesome! Great Job! Thanks for watching!

[@Meech2x]

Just did this and when. I went to tart mower it would slowly turn then not turn over.Now it just clicks when I turn key.What can it mean?

[@IndRepair]

Probably dead battery, loose connection or bad ground wire if just clicking. Does the engine turn free by hand?

[@Meech2x]

@@IndRepair like if I rotate fly wheel?

[@IndRepair]

Correct

[@Meech2x]

@@IndRepair yes it does

[@IndRepair]

Check the battery and connections next

[@elmore119]

But if you already had it taken apart why not go ahead and relapse the valves

[@IndRepair]

We estimated this to the customer and they declined the service

[@elmore119]

@@IndRepair it should be added into the price it's pointless just to do all that work and not do the valve since it's already off we always add it into the price because it only takes like 2 minutes apiece to do valves and about $5 for the valve compound hook it to the drill do chorus and then fine slept everything back together and then put the rest of it on

[@IndRepair]

@@elmore119 Hooking a valve to a drill to lap the valves is not what should be done if doing valve lapping

[@IndRepair]

@@elmore119 Hooking a valve to a drill to lap the valves is not what should be done if doing valve lapping

[@suzieq8379]

tyvm

[@IndRepair]

Thanks for watching!

[@suzieq8379]

@@IndRepair you know I thought mine was the gasket but I have since decided it is my motor mounts, I put lock tight on 2 and they didn't hold cause oil is all up in the holes, after looking under it one of the screws was halfway out, so I decided today I am going to take it and let somone take the motor off and fix those holes and clean all that out so they will hold, lol I do all the work I can to it but I can't lift that motor out,,

[@IndRepair]

Yeah lifting it out is not fun. We usually "roll" them off to another lift. At least it will be fully fixed now

[@suzieq8379]

One of the motor mount screws broke off :(

[@IndRepair]

No good!